Optical inspection device



May 29, 1956 R. H. BIGGS OPTICAL INSPECTION DEVICE 6 Sheets-Sheet 1 Filed Dec. 6, 1951 May 29, 1956 R. H. BIGGS OPTICAL INSPECTION DEVICE 6 Sheets-Sheet 2 Filed Dec. 6, 1951 nvenar 7B 7 ,XGuw, 5M, Luv M2.

L, Attorney! May 29, 1956 R. H. BlGGS OPTICAL INSPECTION DEVICE 6 Sheets-Sheet 3 Filed Dec. 6, 1951 ffil Attorneys a I Inven or mfi i m y 29, 1956 R. HJBIGGS 2,747,463

OPTICAL INSPECTION DEVICE Filed Dec. 6, 1951 6 Sheets-Sheet 4 jun-m- LhAItorneys May 29, 1956 R. H. BIGGS OPTICAL INSPECTION DEVICE 6 Sheets-Sheet 5 Filed Dec. 6, 1951 Inve or is W Attrw y 29, 1956 R. H. BIGGS 2,747,463

OPTICAL INSPECTION DEVICE Filed Dec. 6, 1951 6 Sheets-Sheet 6 Fi ven r.

'iz fi i r eys' United States Patent O OPTICAL INSPECTION DEVICE Raymond Henry Biggs, Forest End, Sandhurst, England, assignor to Power Jets (Research and Development) Limited, London, England, a British company Application December 6, 1951, Serial No. 260,250

Claims priority, application Great Britain December 18, 1950 4 Claims. (Cl. 88-44) It is often desirable to inspect the profile of an object so as to be able, in effect, to see the outline of its crosssection at any number of positions along its length without cutting or otherwise damaging the object. Such visual inspection is particularly desirable for turbine and similar blades but may well be useful for other objects. Purely optical methods for this purpose have the advantage of eliminating mechanical errors, they also avoid damaging the object by physical contact and so make it possible to inspect comparatively delicate object such as wax patterns.

If a tapered object be illuminated around its profile and up to a plane behind its smaller end, which end is left in shadow in front of that plane, with a sharply defined cut-off between light and shadow, the object can be viewed from its smaller end so that its cross-section on that plane or a part of the cross-section appears as a dark shadow against a light surround. Similarly, if the illuminated and dark zones be interchanged the cross-section will appear light against surrounding shadow. The two zones could both be-illuminated but with light of two different intensities or colours so that the cross-section appears in one colour surrounded by another colour, neither of which colours is black. In any case the crosssection is in silhouette against a different surrounding background.

The present invention consists in the method of inspecting an object as set forth in the last paragraph, and also in apparatus for illuminating and inspecting an object in this way. I

Thus the invention is concerned with an optical inspection device having a viewing screen and optical means for projecting on to the screen a silhouette having the profile .of at least part of a chosen cross-section of an elongated object under inspection. The invention consists firstly in the provision of illuminating means disposed beside the object for illuminating part of its length dilferently from the rest, up to a determined boundary plane, with a sharply defined cut-olf in that plane between the two different kinds of illumination, a holder for the object movable to carry the object through saidplane until the chosen cross-section lies in that plane, and means for projecting on to the viewing screen the view looking along the object from one end. Preferably the apparatus projects an enlarged image on the screen; the apparatus then includes a lens so located in relation to the illuminating arrangement that the sharp boundary between the illuminated zone and the non-illuminated or difierently illuminated zone lies in such a plane in front of the focal plane of the lens that there is an image in focus on the screen. The object can then be tilted to a limited extent without the end nearer to the lens masking the view ofthe' cross-section, since the lens, depending on its aperture, can pick up rays that are not cut 01f by the end of the object. Thus the use of the lens also allows of the inspection of objects of various shapes such as non-tapered objects, objects that are twisted along ice their length, or objects with a small enlargement at each end such as a turbine blade with a small shroud element at its tip. Certain objects, however, such as a short turbine blade with a large base at the root end and a large shroud at the tip could only have their whole section projected by special optical arrangements; part of the section may however be inspected by tilting the blade as hereinafter set forth.

The blade or other object can be placed on a work table or in a work holder by which it can be moved lengthwise progressively through the said boundary plane in front of the focal plane of the lens for inspection of the profile of the object at different sections along its; length. It is a feature of the invention that the table or holder can be moved to tilt the blade or other object: through a small angle-preferably both horizontally and. vertically thus enabling blades having excessive twist ora shrouded tip to be viewed, one side at a time. If the: amount of tilt is small, e. g. up to 5, the accuracyof the device is not seriously affected for thin sections. It; can be useful however to examine thicker sections or to use a greater angle of tilt and so inspect one half off an object at a time on an inclined plane which gives a. section considerably different from a section on a normal plane, if the silhouette be compared with the correct sec-- tion on such inclined plane.

According to a further feature of the invention the. illuminating devices, each consisting of a lamp, lamp holder, mask or slide and one or more lenses as neces sary, are slidably mounted on a face for movement parallel to the said plane and held in place by means;

. affording ready adjustment of position, e. g. spring clip,

clamp, or magnetic attraction.

Two forms of construction, each incorporating all the essential features of the invention, are shewn in the accompanying drawings of which Fig. l shews the general arrangement of a general purpose inspection device, Figs. 2 to 6 are details thereof, Fig. 7 shows the general arrangement of a compact bench model suitable for inspection of the leading edges of turbine blades and Figs. 8 to 10 are details of this bench model.

In the particular form of construction shown in Figs. 1 to 6 the apparatus is mounted on a table 1. A holder 2 standing up from the table 1 carries the lens element 3 which may be a compound lens. In front of the lens element 3, supported by a bracket 4 from the table 1, is a fiat metal ring plate 5 presenting a plane surface 5a which is accurately normal to the optical axis of the lens element 3. Several illuminating devices preferably viewed from the axis XX of Fig. 2 in Fig. 4. Each device consists of a case 7 containing a lamp-holder 8, an ordinary electric lamp 9, and the optical unit consisting of tube 10 containing a sharply delineated mask 11, the arrangement of lenses 12 and the spring 13.

The mask has a sharp edge 11a (Fig. 4) which,- whenf the case 7 is in place on the plate 5, is parallel to and accurately positioned relatively to the face 5a so that the light projected is cut off sharply in a boundary plane precisely located relatively to the lens element 3; thus a zone extending from this plane towards lens element 3 is more brightly illuminated than that to the other side of the plane. The optical system of each illuminating device 6 to 60 gives a considerable depth of focus, sothat the sharply defined cut-off is still obtained on a surface illuminated by the device when the distance from the device to the surface is varied. :This allows the.

' oma; modification of ring plate:Siformedasa-magnetis devices 6 to- 6c to bemoved about on thesurface 5a" without having to be accurately adjusted to a particular position relatively to axis X- -X orre-adjusted as an object under-inspectionismoved: An ordinary-electric filament-lamp-9 canbe used, e;- g. amotor'car-head- 5 lampbulb which can be supplied from a low voltage source; or a standard type ofsmall projection lamp. The lighbfrom one lamp does not tend to interfere with another and; no masksare necessary between devices 6 t0-6c. The tube-101E slidablyadjustable relatively'to 10 lamp 9 and can be clamped in position by screw and nut'14.

Each= lamp case 7 has= aspring clip 7a-which carries the= springadjusting screwand which can he slipped over-the inner edge-of the ring-53 the-point=ot scre .v 15'- 15 being held by-spring=7lz=against th'e rear of the ringplate' andrholding.- the case- 7. with the points'of three accurately preset: levelling screwsw 16 thereon bearing against thesurface; 5a1so that the-cut-off is-in-the desired' plane'relatively. to I the lens element a 3; The spring-clips 7a apply sufficient frictional gn'pto hold the cases- 7 firmlyin placewhen theyhave. been adjusted bybeingmoved about over the surface 511.

The lamp cases, insteadof being held byspringclipsor screw clamps or'a combination of-thesecould haveaflat-back of magnetic material accurately positioned relativelylo. the edge ll'aofithe. mask 11; and be held-- chuck or faceplate. Again, if thezl'ing plate beof magnetic-,matetialtheflat back ofeach-case 7f'cou1d'be formed by; the poles ofa permanent v or. electro-magnet.

Slides la; are vformedon: the table 1. To adjust the' distance; between the boundary plane of the: illuminatingsystem; and the lens element the lens holder: 2i. and the; bracket 4 can be;moved relatively, along the; slides 1a and then locked in place.

In front;, o f; the; ring: plate15 .on.the;table2 1; a work holder 17, shownin detailinuFigsi 5 1and;.6.is: adjustablyw mounted as setforth below; Fig; 5 shows the: holder. in elevation as seen from the frontof the whole aPPfira-. tus while Fig. dis a section;along:the axisr;X--X or. one parallelthereto through the. centre:of the;holder.. This holder 17 is a bracket on which a lower jaw 18% isdetachably fixed and an upper jaw 19 is hingedby. the;.hingepinss 20 carriediin lugs on thezholder. Jaw; 19 is;held in .the clamping, position by; the-engagement therewith of the headofheaded plungcr. ZLslidablti through .the. holder .17 under the-force of springlxeforzunclamping; the; plunger can. be lifted byythe button; ;2 2..:1attache.d:.toi. theplunger. A turbine blader;38:.is;;shown;;clamped. by:

7 its ,fir tree-root. in Fig. 6; V the blade scam bercunclamped bypushingonbutton 22. I

The work-holder has a.stem 17a;;by:-which it;is;detach-v ablyspivoted on 1 part 24a of a carrier ,-24,;which; ,by means. of the, usual L lead screw rotated i by handle :25; cannbe r i d-and; zlowered onv r ical s idesion .thegbracket 26:; whichinturn can rotate abouha vertical :axis lorpivotz 21 11thel r ssus dleli -1 The lattenican be ;-traversed-; on-,.cross slides; z9arof'the mainqsaddle bynhandlet e. main saddle being; movable-.-;;.a1ong the :slides-.:1a so by the handle; 31.1 Eor ,;tilting the;;.work;holder:IT the part; zgta can be turned aboutraihorizontal :axis on car riei124 .the-Arlt :1 knob laz; which .co-operatesewith :scale 33,: t sh wIthe fangle of :tilt. Thusethe; workholder is a mounted onagseriesmfi slidesi which,- .by .separaterlead 5 screws andhandles; allow adjustment-stewardsiiandaway'- fron :t; -the lens .element 3, transversely at-rightangles totheznptical. axis .Xi X of the -lens:and up -and down-r Sincestheholder: 17 is-mounted ;by=verticaliand horizontal pivots aeright angles; an-objeet held intheh'older -l l and:pointingatowardsl -the leuselement- 3 can-beg titted UPuaQd 'dOWfl; turned through -an adequate -angle aheut'r a -.vertical axis;--'andturned ahout the lengthwiszaxis of the:=-objeet-.- A transparent"screed-3fiis mounted'fahovei thework heldere 'Ih'espace below-can-b'escreened from 4 unwantedextraneous light by curtains 37'. A reflector 35 mounted on bracket 34 on the table behind the lens reflects on to the screen 36 the image received from the lens element 3. For inspection of turbine blades or objects of that size the system. should produce on the screen an image. magnified notlessthantentimes, further local magnification being 'obtainal'aleis desired by use of a magnifying glass .in=front= of. the screen? For "carrying out aninspection of a turbine: bladejdfi,

it is held byiits root in'the work-h0lderi 17. withi its tip pointing. towards the lens.3 and.the.work.holder adjusted by handles 30 and 25"and knob 32 until" the b'lade'is lying more or less alongthez'opticalfaxis: of the lens. Four lamps in theirvcases--7:are1slid over the plate '5 at about equal distances from the.axis.X-X and subon translucent paper, film, or other material stretGh'edoVerthe screen;'.the drawngs-may be on a-roll er-blindwhich canbe drawn-over the screen. Thedensity of the shadow around the blade outline shouldnot beiso great as td hide the" line of the drawingif the blade b"e 'und'er-'si2e.-' If the-masks "11- be turned through in"-the -tubes' 10" the lamps -will' then illuminate only a part offtHe-bladej to theside of the-boundry plane remote from the lens 3; the profilewould-then appear on theis'creenin' shadow against a light background andagain' the shadow: should not be "so dense as to hide'the'line'of the drawing shouldj' the-blade-be'over size; It has-been'sofar assumeddhat" the-masks 11 are opaque; but: instead/they could beffori example coloured transparencies'so that part of .the' blade,

instead of*-being*-in-= shadow; would" be illuminatedinf a" white-coatingeither not thickenough toalter theprofilefl materially or of accurately known'thickness."

The simplicity of" the: whole combination" of devices makes it'possi-ble, if. desired, to provide" an 'ar'rangem'ent with* the lenses and illuminating assemblies duplicated side by sidewith double workholders :to carry two blades or other objects in correctrelati'onto each? other; this. allows two"imagesoue of the work profileaudthejother. ofthe corresponding profile of "a standard atterjntto be thrown 'on to.5a dduble'isize screen (rulefd"ini s uares) adjacent to each'other for comparison'orfotonein'iageto 'be-superimposedon the other.

It'will be .clearjthat one essential feature'of the .iliven-Q tion is'that'it'produces' on the screen. a, silhouette} and 7 not a *mere' line. showing the outline ofjj'the j blade; thus I thie 'outline of'the 'hlade'is,sharplyi indiated hygtheIboun ary between" two 'difierently illiil'nitiatedfzonesa A ifliithetlessential'feamre of the invention. distinguishes Qitfribmlh usualj. shadowgraph." projector .wlier.v nlith, object lie between-the lens and the source of IighFandis" illuminated from the rear so that only the maximum profile can appear on the screen; illumination from the sides of the object by means disposed around the object in the present invention allows the profile at a chosen cross-section to be projected.

If the object being inspected be a long tapered object that extends at each end beyond the beams of light from the illuminating devices there will be a wide band of light on the object. Thus with the illustrated disposition of the mask 11 a small shadow may appear in the centre of the light silhouette of the section, which will not disturb the user since the section still appears in silhouette and not as a line.

If drawings be used for comparison they will usually be of cross-sections on planes normal to the axis of the blade or other object. When a thick object is viewed by tilting by means of knob 32 or the angle of tilt is considerable, special master profile drawings may be used, when inspecting the projected profile, so drawn as to compensate for the distortion of the profile when tilted to a predetermined angle. Alternatively in a double arrangement the work and a master pattern can be both tilted together to the same angle and compared. The method of the invention in some cases allows inspection of objects with enlarged ends forming masks, e. g. blades with shrouds at each end; by tilting the object, the top and then the bottom of one end of the blade can be viewed from about the middle to the end remote from the lens, after which the other end can be viewed by reversing the blade in the holder.

Such a method is particularly useful when examining leading and outlet or trailing edges of turbine blades, since by tilting the blade sufilciently it may be arranged for one end to move up to and past the projection lens which may therefore be of short focal length, thus allowing the whole length of the apparatus to be reduced and improving the intensity of illuminations of the screen without reducing the magnification. This is the principle of the form of constructon shown in Figs. 7 to 10, wherein moreover a wide band of light is directed on to only a portion of the periphery of the object, such as only the region of one edge of a turbine blade.

In the general outline of the apparatus shown in Fig. 7 the front hood 39 (with curtains 37) and the removable rear cover 40 are on the table 41. A holder 42 standing up from the table carries the inclined lens element 43 which is of short focal length. In front of the lens element, supported by feet 44 on the table 41, is the inclined flat metal ring plate 45 on the rear plane surface 45a of which are slidably mounted illuminating devices indicated by 46. The work holder unit 57 consists of a Work clamp as in Figs. 5 and 6 mounted for sliding on the table 41 towards and away from lens element 43 and for tilting (relatively to the inclined optical axis of the lens) about an axis transverse to the table, as already described with reference to Fig. 1 but the movements of the workholder up and down and across the table are not essential. The reflector 55 mounted on bracket 54 on the table 41 behind the lens reflects the image received from the lens on to the screen 56 in front of the work holder, which screen can be viewed by looking into the open front of the hood 39.

The illuminating and optical systems, without the front screen 56 and the work holder, are shown in more detail in Fig. 8 in which for clearness the lens holder 42 has been slid back from the ring plate 45. Fig. 9 is a view of the illuminating system (without the feet 44) looking in the direction of arrow IX of Figs. 7 and 8, while Fig. 10 is an enlarged detail of the masking arrangement.

The ring plate 45 has an arcuate slot 45b along which can be adjusted the screwed stud portions 48a of the clamps 48. These clamps 48 can slide around the ring plate 45 and have flat backs bearing on the face 45a;

6 they can be clamped in position by the nuts 49 on the stud portions 48a. The illuminating device 46 consists of the case 47, similar to the case 7 without the clips 7a, the tubular optical unit 50, and contents (lamp and lenses) similar to those in case 7 and tube 10 of Fig. 3. The mask 51 however now consists, as shown in Fig. 10, of the cap on the end of the tube unit 50 and has a wide slot 51a which causes a wide band of light to be thrown upon the turbine blade under inspection. As only the region of one edge of the blade has to be illuminated, only two illuminating devices 46, and 46a are shewn in Fig. 9; in some cases a single one will sufiice, or if desired a third can be added since the units can readily be removed by undoing nuts 49. With the lens holder 42 in position the blade is close to the lens. For clearness a blade 38 is shewn, without the holder, adjacent to the illuminating system and the band of light is indicated thereon. By traversing the holder as already described with reference to Fig. 1 the blade can be moved progressively through the ring plate 45 towards the lens element 43 and until, if necessary, the blade tip has passed under the bottom of the lens. The image on the screen 56 will be a light silhouette of one edge of the blade against a darker background or vice versa.

In the former assembly the boundary plane of illumination is determined by the edge of mask slot 51a nearest to surface 45a and the profile checked is the outermost edge of the light silhouette. If'the angle of the blade to the optical axis be suflicient for the image to be considerably different from the shape of the edge on a plane normal to the blade axis the image is compared with a drawing on the screen of the edge as it should appear on the inclined plane.

What I claim is:

1. In an inspection device for inspecting the profile of at least part of a chosen cross-sectional plane through an elongated object under inspection by illuminating the object around said profile and viewing the object from one end thereof, illuminating means consisting of a member having a face transverse to the direction of view, and a plurality of illuminating devices, each slidably adjustably mounted on said face for movement parallel to said plane, each said illuminating device including a lamp, a lamp holder, a lens system positioned to direct a beam of light from said lamp on to the object under inspection and a sharply delineated mask positioned in said beam, each said illuminating device also having a contact surface bearing against said face, the said contact surfaces in all the illuminating devices being accurately preset at the same distance from the cut-ofi edges of the sharply delineated masks.

2. An optical inspection device for projecting a silhouette having the profile of at least part of a chosen cross section of an elongated object under inspection including a lens system, a holder for carrying the object in a position lying along the general direction of the optical axis of the said lens system, illuminating means disposed around the object for illuminating the object along a substantial part of its length up to a determined boundary plane differently from another substantial part of the length beyond said plane with a sharp cut-01f in that plane between the two dilierent kinds of illumination, the said boundary plane being substantially perpendicular to said optical axis, said illuminating means comprising a member having a face transverse to the optical axis and a plurality of illuminating devices each slidably adjustably mounted on said face for movement parallel to said boundary plane, each said illuminating device including a lamp, a lamp holder, a lens system positioned to direct a beam of light from said lamp onto the object under inspection, and a sharply delineated mask positioned in said beam to vary the nature of the illumination over part of the object with a sharp cut-ofl from one kind of illumination to the other in the said boundary plane, and a viewing screen positioned to receive, -thronghsaidfirst-nientioned lens systern, a proje c- 9 a V w lobking q he: Ob e from h m which is pointing; to; the-lens,- means' for rnoving said 4.- An op tical inspection device for projecting v asilhonette havingthe. profile of: at least partro f a chosen crosssectionof an elongated iobj ectunder inspection in.

cluding a lens: systern a holder for carrying the object in a position lyingsalonglhe general direction of the optical axis of the saidilens systeni illurninating means-disposed'around the objection illuminating the object along a substantial part of itslengthnp; toa determined boundary plane difierently from another, substantial part of the length beyond said plane witha sharp-cut-ofi that planebetween the-two different kindspf illumination, the said boundary plane being.substantially perpendicular to said optical axis, said illnrninating'rneans comprising, a, member'havinga face transverse to the optical ax is and a plnrality of illilininating devices each slid ably adjiis tably mounted on saidgface for movement parallel to said v d Pl n a h Said. ill na -1 ev n ud n a lamp, a lamp holder, 2. lens systeni positioned to direct.

a beam of light from said-lamp. onto theobject under inspection and'a sharply, delineated mask-positioned in said beamtovary the natilre of the illiimination-over part1 ot the objeet with a sharp-cut-ofi froln one kind oi illnminationto the other; inthe said boundary plane, and a viewing screen positioned to receive, through saidfirstmentioned. lens system,. a/ projection of a'viewlooking;

along the objectfro'ni the end which is pointing to the lens-,meansfor relatively moving the holder with respect totlieilluminating meanso efict relativelrnovement of the objectithrongli saidipla'neiintil the desired cross sec=- tion lies inthat'plane and nieans for-pivoting said'h old e'r" to tilt'Ithe aXisio'f the object'at'. an angle to'the saidoptical' afre'nce'citd thefil'j of this patent" UNITED STATES? PATENT-Sf 2,256,102 Re son; Sept'.'16,',1941"v 2357;5-42' Pf il" Sept. 5, 1944' 2574119 Mottu Nov. 6; 1951 cronstedt Mar. 3,1953" w l u 

